3223 ultraroof380 installation A4 68pp AW JAN 2018 MAIN · 6 Fixing panel to beam 300mm CTRS RRR...

V4 | February 2018

ULTRAROOF INSTALLATION GUIDE

2

Dear Customer,

Thank you for choosing the Ultraframe Ultraroof380 product. This guide is designed to make tting as straightforward as possible.

Before you commence installation of the roof, please take a moment to read the guide.

This guide is written on the basis that a quali ed surveyor has undertaken correct checks for the capability / structural performance of any existing framework / walls / foundations to verify they are t for purpose. Any feedback - positive or negative - is welcomed so we can make our systems even better.

Please contact the Tech Support Team on 01200 452 918 or email [email protected] FITTERS:

Look out for this registration form and pass to the homeowner please

CONTENTS PAGE PAGE

Tools required / items not supplied 3Fixing summary 4-8Ultraroof380 tters tips 9Documentation checklist 10Box beam cross section assembly 11Product overview / assemblies 12-13Fitting sequence for box beams, OSB boards 14Box beam on window frame 15Box beam on brick work 16Box beam on brick and window frame 17Installation - Solid - Georgian - Box eaves beam 18-22Installation - Solid - Georgian - Structural framework 23-24Installation - Solid - Georgian - Panel assembly 25Installation - Solid - Georgian - OSB boarding 26-27Installation - Georgian - Water proof under layer 27-28Installation - Georgian - Hip spines/Ultratile/Cappings 29-34Installation - Georgian - Fascia so t and guttering 35Installation - Down lights 36

Installation - Plasterboarding 37-38Installation - Plasterboarding columns 39Installation - Georgian - Roof glass 40-46Installation - Lean-to solid 47-50Installation - Lean-to glazed 51-53Installation - Lean-to glazed to adjacent wall 54Installation - Gable end solid 55-57Installation - Gable reinforcement 58-59Installation - Gable standard so t 60Installation - Gable extended so t 61Installation - Box beam on column 62Installation - Tudor nishing 63-64Installation - Beam jointing post 65-66

3

Clamps 2.5m straight edge

Small sca old tower & Youngman boards

Drill/imapct screwdriver

8mm Hex head socket

10 and 17mm spanner

Long (1,500mm) and short spirit levels

Tape measure

Plumb bob and string line

Acro prop

Heat gun

6mm drillbitStaple gun

TOOLS REQUIRED

NOT SUPPLIED:Several items are not supplied by Ultraframe as they are easier and cheaper to source locallyThese are:-

• Velux roof windows and EDL ashing kits (the roof arrives prepared for Velux)• Anchor or Masonry xng bolts to host wall• 12.5 foiled backed plaster board and skimming beads• LED ( re resistant) lighting• Internal 20mm x 50mm and 25mm x 50mm timber plastering battens• Timber support props (75mm x 50mm) beam support• Structural support (available from Ultraframe)• Frame to boxbeam xings

For everything you need to know about Ultraroof380 including guides and installation videos visit

www.ur380info.co.uk

4

CHA0064.0 x 13 self drill

wafer head

PHILLIPSSCREWDRIVER

BIT

PLEASE USE THE SUPPLIED FIXINGS WHEN INSTALLING THE ULTRAROOF380 TO ENSURE A SECURE AND CORRECT INSTALLATION.

FIXINGS SUPPLIED Below shows the various xings supplied for an installation of an Ultraroof380. These should be found in the box containing this document.

NRBA 0124.8 x 32 Phillips CSK HD S/Drill

BPS 0104.8 x 80 baypole screw, self drill

Phillips wafer head

NRTS 0504.2 x 25 wafer head Self drilling screws

RRX 0255.0 x 50 C’SNK pozi

heco x wood screw

RRR 0255.5 x 32 Hex head

self drill screw

NRRSA 005BL5.5 x 90 Hex washer

head tek screw

NRBF 0504.0 x 40 Deck-tite pozi countersink

screw

NRES 0044.8 x 32

pan head self drill

NRSF 0124.8 x 38

pan head self drill

NRAF 0255.5 x 50 self drilling

C’SNK, winged screw

PHILLIPSSCREWDRIVER

BIT

PHILLIPSSCREWDRIVER

BIT

PHILLIPSSCREWDRIVER

BIT

PHILLIPSSCREWDRIVER

BIT

PHILLIPSSCREWDRIVER

BIT

PHILLIPSSCREWDRIVER

BIT

POZISCREWDRIVER

BIT

POZISCREWDRIVER

BIT

M8 HEXSCREWDRIVER

BIT

M8 HEXSCREWDRIVER

BIT

ULTRAROOF380 FIXING SUMMARY

NRTT001Tile screw xing tool

NRTT0014.2 x 25 Wafer head piercing point screw

PHILLIPSSCREWDRIVER

BIT

5

Fixing support shelf to existing frames

6 xings per corner

NRBA 0124.8 x 32 Phillips CSK HD S/Drill

Ultraframe recommends HILTI chemical anchors where speci ed and expanding anchors in other locations (to resist pull out forces). Using HILTI product codes/descriptions, use a HIT-V 80mm x M8 threaded anchor (stud*) fastened into a 10mm clean drill hole with gun injected mortar or adhesive capsules (with a minimum 80mm embedded) - always rigorously follow manufacturers guidance www.hilti.comIn addition Ultraframe recommends the following alternatives;Fischer M8/M10 masonry injection anchor FIS VRawl Fixings M8/M10 CFS RM50 or CFS RP30* Design load for each stud 2.5k

Fixing hanger bracket to wall

Fixing through head of window frame into beam

4 xings per bracket

Securing corner cleats

Securing upper box beam cleats

200mm from corner, 450mm CTRS

NOT SUPPLIED

NOT SUPPLIED

12 per cleat, 6 through pre drilled holes, 6 through gutter support channel

NRTS 0504.2 x 25 wafer head self drilling screws

6 per cleat


Fixing beam to corner

6 xings per corner


heco x wood screw

Fixing wall brackets to the beam

6 xings per bracket


heco x wood screw


NOT SUPPLIED

Fixing ridge hanger to the wall

Minimum 2 xings

Fixing hip bar support brackets

4 xings per bracket


Fixing ridge to ridge hanger

2 xings

RRR 0255.5 x 32 Hex

head self drill screw

FIXING LOCATION SUMMARY

6

Fixing panel to beam

300mm CTRS

RRR 0255.5 x 32 Hex


300mm CTRS (Pre drilled holes)

RRR 0255.5 x 32 Hex


Fixing panel to hip and ridge

300mm CTRS

RRR 0255.5 x 32 Hex


Fixing panel to starter


NOT SUPPLIED

Within 200mm from ridge/eaves,another equidistant

Fixing starter to house wall

Fixing extention batterns to beam

NRAF 0255.5 x 50 self drilling

C’SNK, winged screw

2 xings per batten

Fixing OSB to panel and beam

24 per panel


screw

Fixing steel hip plates


300mm CTRS (Pre drilled holes)

Fixing aluminium ridge plate


Pre drilled holes

Fixing UltraTile starter tile strip


x through all available holes

Fixing Ultratile panel

NRTS 0504.2 x 25 wafer head

piercing point screw

11 per full tile


Fixing hip spines


500mm CTRS per side

7

Fixing intermediate glazing bar bracket


Pre drilled holes

Fixing glazing bar at box beam shoe


Pre drilled holes

Fixing glazing ridge to glazing bars


Pre drilled holes

Fixing glazing bar to box beam external face


2 xings either side

BPS 0254.8 x 80 baypole

screw, self drill Phillips wafer head

Securing glazing bar against panel timber

500mm CTRS

Fixing glazing support section


200mm CTRS

Fixing ridge top cap

Pre drill MAX 750mm CTRS


head tek screw

Fixing end caps

Screw port

NRES 0044.8 x 32

pan head self drill

FIXING LOCATIONS FOR GLAZED ROOFS The following shows an overview of where the supplied xings are used based on a roof contaning glazing.

Fixing glazing bar shoes at box beam


Pre drilled holes

Fixing glazing bar adjustable connection bracket


Pre drilled holes


BPS025

RRR 0255.5 x 32 Hex


Fixing through ridge into purlin 300mm CTRS

8

Pre drilled holes

NRES 0044.8 x 32

pan head self drill

Fixing glazing bar end caps


head tek screw

500mm CTRS

Fixing ridge under capping central

Fixing black architrave

300mm CTRS

Fixing screen framework at ridge


screw

300mm CTRS

NRSF 0124.8 x 38

pan head self drill

Fixing tile stop aluminium 300mm CTRS

Fixing tile screen

Single xing


screw

BPS 0104.8 x 80 baypole

screw, self drill Phillips wafer head

Fixing through purlin into cassette

Single xing


heco x wood screw

Re-fi tting panel timbers

origional xing holes

Fixing ridge under capping into tile stop


500mm CTRS


Half ridge intermediate bar shoe

CHA0064.0 x 13 wafer head self drilling screws


screw

9

ULTRAROOF380 FITTERS TIPS

If this if the first time you’re fitting an Ultraroof380 we suggest you familiarise yourself with the Installation guide before you start.

Ensure that you have all the key documents outlined on page 10 and all the correct tools on site, these are outlined on page 3. If you don’t have any of the key documents, please call Technical Support at Ultraframe on 01200 452 918 - have your order number handy.

For everything you need to know about Ultraroof380 including guides and installation videos visit

www.ur380info.co.uk

Here are some top tips from Ultraframe to help your installation run smoothly.

1. Ensure the beams are laid on top of the frames in the correct order. The correct ‘fitting sequence’ is shown on page 14 of the installation guide.

2. When positioning the beams check the dimensions vs the critical dimensions sheet supplied with the roof. Start by ensuring the beams that attach to the house wall are parallel and the correct distance apart. Ultraroof380 will accommodate slightly out of square bases and frames. Please call Paul Saltis on 07740 067070 for advice if this is the case.

3. In order to ensure the stability of the beam it needs to be sufficiently supported. Details are shown on the flyer included with the beams and on page 19 of this guide.

4. Always use the fixings, sealants and adhesives specified within the installation guide in order to ensure the strength and water tightness of the roof.

5. Don’t forget to prop the ridge as shown on page 23.

6. When fitting the batten extensions to the box beam, ensure that the lower end of the batten extension rests against the edge of the aluminium extrusion on the front of the box beam. This will ensure the OSB is in the correct position. See detail on page 26.

7. Start by placing the OSB boards next to the box beam first. Work your way around the box beam with the OSB before working your way up to the ridge. Only remove the props once the OSB boards and steel hip plates are fixed in place.

8. The waterproof membrane can be fitted when damp, but always remove surface water before fitting if it’s been raining. 100mm overlap is sufficient on the roof surface with 150mm lapping up the wall.

9. Always use tile fixing tool provided. This will prevent over tightening.

10. The tiles are designed for expansion and contraction. DO NOT BE TEMPTED TO FORCE THE TILES TOO CLOSE TOGETHER. Always work to the insertion lines ensuring the spaces between the tiles are even across the roof. Use the starter tile strip to guide you and refer to the tile leaflet included for further information (ref p29).

11. Look out for the handy guides supplied with products for extra tips on fitting.

10

DOCUMENTATION CHECKLIST SENT WITH EACH ROOF

General pointsChoose a suitable area for unpacking the components and always check them before tting. Any claims for missing or damaged parts are only accepted in line with our standard terms and conditions of sale. Health & safetySite safety is paramount. The Construction (Design & Management) Regulations 2015 apply to the whole construction process, on all construction projects from concept through to completion. Compliance is required to ensure construction projects are carried out in a way that secures health and safety. The installation company shall be responsible for the safety of all of the tting team, the customer and members of the public.

The Surveyor should have carried out a risk assessment to reduce risk on site and this should have been discussed with you prior to starting.

Please use safe working platforms and ladders that comply with BS EN 131. Always use equipment in line with manufacturers recommendations. Personal Protective Equipment – such as goggles, mask and ear defenders – should be used when, for example, grinding out for the ashing. Careful consideration should be given to the safe disposal of all packaging – Ultraframe packaging is predominantly made from recycled materials and can be readily recycled.

ProductThe Ultraroof380 kit is supplied with a location plan and, of course, this installation guide. The location plan is used to match individual components to their respective position on the roof.

The SuperstructureCheck the side frames are level all round. Before starting to install the Ultraroof380, please check the condition of the host wall and whether it’s plumb – depending upon what you nd, these conditions can seriously a ect the nal integrity of the roof.

Check the condition of the host wall as this may aff ect the quality of the fi nal installation. Check the host wall is plumb - any running in/or out should have been accounted for by the surveyor. If not, the ridge and starter bars may require packing out with aluminium shims. Correct alignment in this area is critical to a successful installation - Plumb frames/level ridge. Only use the specifi ed fi xings - never be tempted to substitute alternative sizes/gauges.

HOST WALL

PRE INSTALLATION CHECKS

Check you have:1. Critical set out dimensions2. Confi rmation of roof order3. OSB layout4. Tile layout5. Panel layout6. Modesty panel layout7. Component location plan8. Ultraroof380 component box list

11

(Window frame thickness may vary)(when using 70mm frames)40mm

70mm

284mm

UltraTile in 3 colours

Powder coated tile starter support

Integrated Marley Classic gutter system - bracket snaps onto aluminium gutter support channel

321.5mm

Counter battens

190mm Unidek aero panel,

0.16W/m2 ºC (240mm panel to follow)

Waterproof breathable membrane

OSB3 (Oriented Strand Board) - tongue and groove

to 4 sides

OSB3 (Oriented Strand Board) - structural grade

Fascia board

Ultratile starter strip

High performance corrosion resistant steel

High performance corrosion

resistant steel

High performance mineral wool insulation

25x50mm timber battens (Not supplied)

Double plasterboard when roof is

glazed

12.5mm foil backed

plasterboard(Not supplied)

Window frame

380mm

Internal Frame (Datum)

BOX BEAM CROSS SECTION ASSEMBLY

Soffi t channel

Additional timber batten(Not supplied)

Alternative (only option if sat on super-insulated columns) - see Appendix 1.

210mm

(Window frame thickness may vary)70mm

151.5mm172.5mm

Standard Soffi tNOT SUITABLE FOR SUPER INSULATED COLUMNS

Extended Soffi tMUST BE USED ABOVE SUPER INSULATED COLUMNS

12

Ridge glass glass

Beam glass Beam solid

PRODUCT ASSEMBLIES

Ridge solid solid Ridge solid glass

265 boxgutter

13

PRODUCT ASSEMBLIES

Boxgutter glass Tapered boxgutter

Wallplate glass Wallplate solid

Bars Gable extended

Lean to gable stiff enerLean to only

Lean to roof gable end frame sti ener is NOT supplied as standard. Must be requested if required (for example above door openings). Please refer to Ultraframe if tting bi-folds to gable ended or gable ends on lean-to roofs.

14

FITTING SEQUENCE BOX BEAMS OSB

IMPORTANT: FOLLOW THE FITTING ASSEMBLY SEQUENCE

KEY: OSB BOX BEAM

1 2

3

1 2

5

3 4

VICTORIANGEORGAN

BOX BEAM SUPPORT SHELFGEORGIAN STANDARD SOFFIT GEORGIAN EXTENDED SOFFIT

96mm 207.5mmInternal frame line Internal frame line

15

The most common kind of situation for installing an Ultraroof380 will be existing conservatries roof replacement. This means that the roof will x to the top of the window frames of the original conservatory. The details for xing a box beam to the top of window frames as shown below.

DOUBLE PLASTERBOARD

STANDARD SOFFIT

DOUBLE PLASTERBOARD

BOX BEAM ON WINDOW FRAME

STANDARD SOFFIT 40MM

EXTENDED SOFFIT 151.5MM

16

BRICK SOFFIT DEPTH 94mm

OFFSET TO INTERNAL BRICK (FRAME DATUM)

DOUBLE PLASTERBOARD

FAC

mm

mmmm

mm

FRAME DATUM

300

BRICK

DEFAULT STANDARD SOFFIT

OFFSET TO INTERNAL BRICK

DOUBLE PLASTERBOARD

ON BRI

mm

mm

mm

mm

mm

FRAME DATUM

(FRAME DATUM)

SOFFIT DEPTH 40mm

A common instance with Ultraroof380 will be that it is sat on brick work for support. If this is the case there are di erent details of how the roof sits on the brickwork and depending on which of these is required give di erent results. Below contains the details for xing a box beam to the top of solid brick work.

BOX BEAM ON BRICK WORK

STANDARD SOFFIT WITH BRICK

FACE

N BRICK WALLFFIT WIDTH WHEN SITTINGON BRICK WALLSOFFIT WIDTH WHEN SITTING

EXTENDED SOFFIT WITH BRICK

17

BRICK

OFFSET TO INTERNAL BRICK

DOUBLE PLASTERBOARD

FRAME DATUM

SOFFIT DEPTH 40mm

mm

mmmm

mm

Some situations will have a mix of window frames and brickwork that will support the length of the box beam. Below contains the details for xing a box beam to the top of window frames with brick work.

BOX BEAM ON BRICK AND WINDOW FRAME

BRICK

DEFAULT STANDARD SOFFIT

DOUBLE PLASTERBOARD

ST

INC

mm

FRAME DATUM

mmmm

STANDARD SETOUT

INCLUDED

SITTING ON A BRICK

BOX BEAM ALIGNING WITH BRICK FACE

BRICK WORK ALIGNING WITH INTERNAL FRAME DATUM

FACE

18

GEORGIAN INSTALLATION SOLID ROOF BOX EAVES BEAM

NRSS 090Beam support shelf for 90° corner


NRBA 0124.8 x 32 Phillips CSK HD S/Drill. 6 xings per shelf.


2

Secure support shelves to frames with 6 x xings (3 each side) 4.8 x 32mm Phillips counter sunk self drill screw (NRBA 012).

Timber positioning spacers attached to underside of support shelves. Ensure these abut internal frame (also shown below).

3a

If replacing an existng roof fold back the ashings, safely remove the existing roof and recycle it. If plastered, certain areas will need removing. Fixed light sealed units will need to be removed to allow xing of box eaves beam. Remove old silicone from head of all frames. NOTE: If tting onto super-insulated columns refer to page 62.

1

Using low modulous neutral clear silicone, apply generous beads to head of frames and corner post. Locate the OSB beam support shelf’s (NRSS 090) to the front corners.

5

Apply beads of low modulus neutral clear silicone to remainder of all frame heads. Seal along inner legs.

6

Now t the NRWB001 box beam wall brackets - one to each side - Bracket sits 8mm inside internal frame line and is set 9mm above window frames (measured to underside of bracket). Remove any interfering plaster work. Bracket must go back to host wall. Not required if sat on masonry, galvanised straps to be used (not supplied).

4

Mark positions for resin anchors (not supplied) appropriate to substrate. Try to x into solid masonry - 4 xings.

3b

NRSL 001Beam support shelf sticker

19


8

Fix a prop into the steel section of the beam as shown above. Props should be at max 2000mm centres within 250mm from each corner (prop xings NOT SUPPLIED) 75x50 timber props NOT SUPPLIED.

9

Check page 14 for box beam assembly sequence. Lift side beam 1 into position (2 man lift). Set the beam 10mm away from host wall. Position side beam 2.

7

Check the beam is level. Pack o top of frames if necessary. Insert a support prop under the beam. Adjust the height of the prop to ensure the beam is level side to side.

11

With set out sta ush with underside of beam, x to face of beam using 2 x (NRTS050) provided. Sta set-out cleat xed to internal face of box beam. Once xed the sta s will

ensure beams remain parallel to each other.

10

EXAMPLEAbove is a typical 4m x 4m layout, this shows positions of 75mm x 50mm support props and set out sta .

READ BEFORE FITTING BEAMS AND RIDGE MUST BE PROPPED SUPPORTED THROUGHOUT THE

INSTALLATION SEE GUIDE BELOW FOR DETAILS OF PROPS SUPPORT.

DO NOT REMOVE ANY PROPS UNTIL THE OSB AND STEEL HIP PLATES ARE FULLY FIXED INTO PLACE.

PROPS SUPPORTS MUST BE POSITIONED 250mm FROM CORNERS AND MAX 2000mm CENTRES AT THE PROP LOCATION MARKS, PROPS NOT REQUIRED AT

HOST WALL REAR L BRACKET POSITION

BEAMS SET 10MM AWAY FROM HOST WALL

20


16

Gutter support channel extrusion is factory tted but ease out both sections and slide external cleat behind.

17

Line up bottom of the cleat with the bottom edge of the steel using (NRTS 050) xings, t 12 per cleat, 6 in predrilled holes, 6 through gutter support channel extrusion (screws provided).

NRTS 0504.2 x 25mm wafer head self drilling screws

GUTTER SUPPORT CHANNEL

NRBE 135Box beam external cleat required for each 135° mitre



NRTS 0504.2 x 25mm wafer head self drilling screws.[6 per cleat predrilled holes]

19

Then attach top box beam cleat (one to each corner) - these cleats are speci c to the roof pitch. Lay over the mitred joint and position so that the top edge abuts the angle. Then x using 6 x 4.2 x 25mm wafer head self drilling screws (NRTS 050) provided.

18

Use expanding foam where two beams join to seal any gaps between them.

13

Once the beams have been propped and are level, check the rear L brackets and pack if required.

14

Width of set out sta matches size given on critical dimension sheet. Pushing or pulling a beam will move adjacent beam the same distance. Equalise so t overhang. Finally check diagonals are equal.

12

Having installed side beams lift the front beam into position, beam 3.

21


20

Check all is level - pack o top of frames if necessary. CHECK THE UNDERSIDE OF THE BOXBEAM IS LEVEL PRIOR TO FINAL FIXING. PROP IF NECESSARY.

If packers used, recheck for being square, also check diagonals (corner to corner measurement). When these checks are complete nally secure by screwing up though head of frames into box beam. Fixings need to be within 200mm of each corner and at 450mm centres using, for example 4.8 x 80mm baypole screw not provided.

21

BPS 010M4.8 x 80 baypole screw, self drill Philips wafer head[ xings 200 from corner, 450 CTRS]

Remove timber positioning dowels (see step 3b). Fix up through the front 90° beam support shelves into the box beam using 6x5.0 x 50mm countersunk wood screw (RRX 025) provided. See xing points at 22b (standard so t) and 22c (extended so t).

22a

RRX 0255.0 x 50 C’SNK pozi heco x wood screw.[6 xings each]

Fixing positions for standard so t.

22b

Fixing positions for extended so t.

22c 23

Fix up through the rear box beam wall brackets into the box beam using 6 x 50 x 50mm countersunk wood screws (RRX 025) provided. Finally ensure all box beam joints are fully sealed inside and out.

22


Once assembled lift and position against the host wall. Slot onto beam support ledge.

With the box beam secured assemble the 3 part ridge hanger. This consists of 1 x ridge hanger plate (NRRI 006) and 2 x aluminium starter bar extrusions (NRPA__/6) .

25

24

Fit the hip bar support brackets (NRHB 001) to the internal front corners of the box beams. One to each corner. The bracket is positioned tight up to the panel support ledge and secured with 4 x 4.2 x 25mm wafer self drilling screws (NRTS 100) provided. Hip bracket supplied for 90°. If super-insulated corner columns used please refer to page 82. For 3 and 5 facet victorians the box beam hip bracket is bent by hand to suit. 135° for 3 facet or 150° for 5 facet.

NRTS 0504.2 x 25mm wafer head self drilling screws.[4 xings each]

26

TONGUEUPPER FACE

NRRI 006

3 facet

135°

5 facet

150°

28

Final position of aluminium starter bar extrusions next to host wall.

27

From critical dimension sheet, check that the UPPER FACE of the ridge hanger ‘tongue’ is set at the correct height. i.e. frame height 2070 + 861 (roof) = 2931mm. Ensure the plate is level. Pack o the host wall with suitable aluminium shims if required. Fix the ridge hanger (NRRI 006) back to the host wall with anchors suitable for the substrate (not supplied).

NRSB 001 Box beam hip bracket required for each hip

23

GEORGIAN INSTALLATION SOLID ROOF STRUCTURAL FRAMEWORK

30

O er up into position the hip bars. Using the tenon on the glazing bar end o er the ‘ball’ into the matching speedlock housing attached to the ridge.

31

O er ridge onto ridge hanger plate, set the rear end of the ridge body 20mm away from the host wall and temporarily secure with 1 x 5.5 x 32mm hex head drill screw (RRR 025). NOTE: This may be adjusted later. IMPORTANT: Support the ridge with adjustable support props. The props must stop in place until the roof is fully built.

29

33

Check critical dimension sheet for dimension x and then nally x the ridge to the ridge hanger bracket with 2 x 5.5 x 32mm hex head drill screws (RRR 025) provided.

34

Using your thumb push down the upper dead lock until ush. DO NOT push up the lower wedge lock at this stage.

32

Sit the lower end of the hip bar on the already installed hip bar support brackets.

RRR025 Hex head drill screw 5.5mm x 32mm [2 xings each]

XBOX BEAM

RIDGE

UPPER DEADLOCK

IMPORTANT: CHECK DIMENSION X

End of ridge body

IF THE ROOF HAS GLAZED UNITS GO TO P40 IF THE ROOF HAS VELUX ROOF SEE VELUX INSTALLATION GUIDE

36

The lower end locates on the box beam support ledge. IF THERE IS GLAZING AGAINST HOST WALL POSITION THE PANELS EITHER SIDE OF THE FINIAL POINT INSTEAD.

37

Next install Unideck SIP panels (one each side) adjacent to host wall.

35

The upper end hooks onto ridge body.

24

39

Fit front central panel in-line with ridge.

38

This pack comes complete with further detailed assembly instructions. For each matching pair of panels along the ridge, a coupler needs to be tted to brace the panels across the ridge.

41

Ensure coupler assembly is nger tight into panel extrusions.

42

Assemble nut and threaded bar. Screw down into ridge body. See note below.

40

Now complete next step of ridge coupler assembly.

Finally, nger tighten the locking nut.

43

RIDGE COUPLER

Ridge Coupler Assembly

Change - No longer speci ed for rst panel pair at host wallReason - Not required in this position due to xings already present under panel at host wall.

GEORGIAN INSTALLATION SOLID ROOF STRUCTURAL FRAMEWORK

25

GEORGIAN INSTALLATION SOLID ROOF PANEL ASSEMBLY AND FIXING

44

From the location plan supplied continue to install all remaining SIP panels (working from the host wall, in pairs, remembering to t the ridge coupler assemblies as you go. FINGER TIGHT ONLY AT THIS STAGE.

46

Screw up into panels through the panel support ledge. DO NOT OVER TIGHTEN TO PREVENT CRUSHING THE PROFILE. Screw at 300 centres using hex head drill screw 5.5 x 32 (RRR 025) provided.

45

Using (RRR 025) screws, screw up through the hip bars (predrilled holes). DO NOT OVER TIGHTEN TO PREVENT CRUSHING THE PROFILE.

Screw through aluminium starter bar extrusions into panels at 300mm centres. Finally screw through ridge section (predrilled holes) again using (RRR 025) provided.

47 48

Lightly tighten roof coupler(s), using a 17mm spanner. Remove hip bar support brackets (p22, step 24). Push lower wedge locks into position on underside of speedlocks to lock out roof (see p23, step 32)

49

Fix aluminium starter bar extrusions to host wall within 200mm of ridge / eaves plus at least one more equidistant between the two. Use resin anchors suitable for substrate. (Not provided).

Foam

3mm nominal Gap

Foam

Box beam

Use expanding foam to ll gaps between panels, panel and box beam and between panels and host wall. (Foam not supplied)

INSULATION IS SUPPLIED IN ROLLS. Cut and install into all hip and ridge sections.

5150

26

GEORGIAN INSTALLATION SOLID ROOF OSB BOARDING

Fit batten extensions onto box beam. Bottom of batten sits against gutter channel and line up with battens on panels. At every corner place a batten either side of the mitred joint on top of cleat.

ENSURE BATTENS SIT TIGHT TO GUTTER CHANNEL THIS SETS THE ROOF TILES.

NREB01020 x 44 x 330mm Tanalised softwood timber battens (pack of 10)

52 53

NRBF050

4.0 X 40mm

DECK-TITE

COUNTERSINK

SCREW

55

Using location plan, lift OSB board panel A into approximate position. Having xed tile starter support onto end of OSB, place against ends of batten extensions to locate OSB. Locate rst row of OSB panels around the roof using tile starter support to position. Work in the same order that the beams were put on (sides toward front).

TIP: USE A 30MM BLOCK TO CHECK OFFSET AT HIPS. Where required support OSB at joints with Batten extensions.

54b

Fit tile starter support, silicone + push t.

54a OSB groove to bottom edge

Tile starter support

NOTE: PRINTED SIDE OF OSB BOARD FITTED FACE DOWN ROUGH FACE

250

100

225

75

PANEL

BOX BEAM

BATTEN CENTERLINE

IMPORTANT The rst row of OSB boards around the perimeter of the roof lock together the box beam and the structural insulated panel. It is important to use the xings shown and follow the screw pattern across along every batten centerline.

NRAF0255.5 x 50m self drilling countersunk winged screw. (2 xings per batton).

27

GEORGIAN INSTALLATION SOLID ROOF OSB BOARDING

Place aluminium ridge cover plate 10mm away from host wall. Fix through the predrilled holes using 4.2 x 25 wafer head drilling screws (NRTS 050) provided.

60

Where required support OSB board at joints with support battens supplied. Battens are 65 x 19 x 700mm long (NRPB 010).

57 58

NRBF0504.0 x 40mm Deck-tite pozi countersink screw (24 per panel)

NRTS050 4.2 x 25mm wafer head self drilling screws.

59

Fit steel hip plates aligning bottom with tile starter support strip. [ xings 300 centres through predrilled holes using NRTS050].

NOTE: THESE ARE SUPPLIED IN TWO HALVES IF OVER 3.2M IN LENGTH TO ALLOW FOR ADJUSTMENT OVERLAP IF REQUIRED.

56

Fit remaining OSB panels working one side at a time left to right, eaves to ridge. NOTE: ALL OSB PANELS HAVE TONGUE AND GROOVE EDGES FOR IMPROVED FIT, SECURE ALL BOARDS WITH 3 FIXINGS TOP, MIDDLE AND BOTTOM USING 4MM X 40MM DECKTITE POZI COUNTERSUNK SCREW NRBF 050 PROVIDED.

61

Image shows roof covered with breathable membrane. Follow the sequence. Membrane part no: RRMA050

Start at eaves and position 150mm up the host wall. Place membrane (as step 63). Overlap each hip (as step 64).

62

The breathable membrane is aligned to the front edge of the tile starter support

63

Place breathable membrane

28

GEORGIAN INSTALLATION SOLID ROOF WATER PROOF UNDER LAYER

64

Work up the roof, overlapping the previous layer by 150mm at pitches of 14 or below and 100mm at 15 and above.

65

Minimum 200mm overlap over hips. Fix using staple hammer with maximum 12mm stainless steel staples. Take care not to cut through lower layers whilst trimming.

On solid roof, the membrane layer straddles the ridge. Slit as shown to allow transition to the opposite side. If the membrane falls short of the ridge plate, install an additional canopy, centrally over the ridge.

66

67

Patch fully taped.

68

Install additional patch of membrane to protect the apex at the host wall. Secure with tape supplied.

Finally cover the previously installed patch with a third layer to ensure positive seal. Staple into position.

69

70

Use tape to seal the layer at ridge end.

29

GEORGIAN INSTALLATION SOLID ROOF HIP SPINES ULTRATILE

GLAZED ROOF SOLID ROOF

If a roof contains rectangular glazing panels, starter strips must be set out from the glazing bar centre.

KEYFitting order is labelled to

Direction of starter strip tting

FIRST STARTER STRIP FITTED FROM HERE

Hip spine to hip spine

Details shown also apply to Victorian shapes.

HOST WALL

Hip SpineHip Spine

1

1 5

2

5

4

3

HOST WALL

Hip SpineHip Spine

FIRST STARTER STRIP FITTED FROM HERE

1 3

2

If a roof contains no rectangular glass panels and is classed as ‘solid’ then starter strips must be set out from the hip spine.

KEYFitting order is labelled to

Direction of starter strip tting

1 3

Tile starter strips are lettered in correspondence with its location shown in the tile location plan. TILE STARTER STRIPS ARE NOT FITTED IN ALPHABETICAL ORDER, PLEASE FOLLOW INSTALLATION SEQUENCE ON THIS PAGE FOR CORRECT FIT.

READ BEFORE FITTING FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN TEMPORARY DISTORTION WHICH MAY MEAN TILES WILL NEED TO BE RE-LAID. Following these instructions allows tiles to correctly ‘ oat’ for expansion and contraction.

1. ENSURE TILES ARE FITTED TO THE CORRECT INSERTION LINE – DO NOT PUSH TILES TOGETHER. Insertion lines vary according to temperature when installed

2. DO NOT OVERTIGHTEN SCREWS

The NRTT001 Tile Screw Fixing Tool can be found with the NRTF050 screws inside the xings component box.

Hold the tool in place as shown whilst installing each screw and remove to ensure a t which is close but not too tight – This is to allow for the expansion and contraction of the tiles.

Correctly tightened

XOvertight

30


1 2

Place starter tile strip on starter tile support, make sure strip is a tight t up against support.

Fix through the central xing hole for temporary tting. DO NOT FIX THROUGH SLOTTED HOLES UNTIL ALL

STARTER STRIPS ARE IN PLACE

3 4

Following the direction stated in the tting guide (see p29). Align next starter tile strip with the standard insertion lines. NOTE: IF AIR TEMPERATURE IS BELOW 5°C, ALIGN WITH THE LOW TEMPERATURE LOCATION MARK TOP RIGHT OF STRIP

Repeat steps 3&4 following the tting order guide until all starter strips are in place and are correctly tted. Once correct, fully x through slotted holes

along the starter strips for permanent x.

5 6

Mark position of hip spines and remove from roof, this helps with tting of the tile panels.

Using the tile location plan provided, locate position of rst tile panel (labelled aa1), slide down onto the starter

strip leaving 23mm from the starter strip edge. This allows expansion of the tiles in warm temperatures.

UltraTile starter strip

Tile starter support

Slide strip up to insertion lines

Central fixing hole Slotted hole

Standard insertion lines

Low temperature, insertion lines

Slotted hole Correctly tightened

Overtight

X

31


7 8

STEP 1 – x through central non adjustable xing hole STEP 2 – x through remaining slotted holes (10 holes)

At normal temperatures, of around 15°C, use the insertion lines indicated red in the image. For low temperature installations, below 5°C, use the single insertion line indicated blue, at the top right of the tile.

9 10

To slot the tiles together, a down and left action is used in one movement. Make sure all tabs have interlocked. Tiles are tted to the roof from left to right bottom to top. Repeat steps 7,8 and 9 for entire layer.

When inserting next layer, overlay tiles in line with insertion lines (marked in red above) on the tile. Repeat steps 8, 9 and 10 until the roof is fully tiled. See tile nishing references on back for accurate t and best results.

L

FIGURE 1 FIGURE 2

If the roof contains full rectangular glass panels, the starter strips MUST be tted from the glazing bar.

If the roof contains no rectangular glass panels, then the starter strips MUST be tted at the hip spines rst.

UltraTile starter strip

Tiles overlap up to guide lines

32

Distance from bottom tile edge to tile overlap insertion lines.This is the amount of tile that should be visible on each layer of the roof. This is a good check to see if the tiles are in the correct position with correct spacing allowances for heat expansion.

H O

S T

W A

L L

25mm FROM EDGE TO WALL

Tiles fi nishing at host wall Tiles fi nishing at gable end

Tiles fi nishing at lean-to ridge Tiles fi nishing at ridge

537mm

REFERENCE DIMENSIONS ONLY - NOT SET OUT DIMENSIONS - site conditions may cause these dimensions to vary.

INSTALLATION TILE FINISHING REFERENCES

33

INSTALLATION TILE FINISHING REFERENCES

1

Lay rst length of the Ultratile starter strip into position (15mm from hip spine centre line) hard against the base of hip spine. IF THERE IS A GLAZING SECTION IN THE ROOF WORK FROM THERE. Temporarily x using (NRTS 050).

2

Working anti-clockwise, temporarily x all hip spines top

and bottom. Spine set 10mm out beyond lower hip point.

Mark position of hip spines and remove from roof, this helps with tting of the tile panels. Using 4.2 x

25mm wafer head self drilling screws (NRTS 050) provided.

3

4

Complete the front facet.

5

Starting with front central facet, continue to lay front row of tiles working from left to right, bottom to top, following the tile location plan.

Using the tile location plan provided, locate position of rst tile panel (labelled aa1), slide down onto the starter strip leaving 23mm from starter strip edge (page 30 step 6). This allows expansion of the tiles in warm temperatures.

6

7

Fully tiled roof. Ensure the 30mm spacing is maintained between tiles on adjacent facets to accommodate the hip spine. Fit the hip spine on completion of the tiling.

8

Continue tiling the roof as above, working anti-clockwise around the roof. Each set of tiles are pushed down, then slid to the left to engage.


(2 each).

TIP: USE STRAIGHT EDGE TO LINE UP SPINES TO HIDDEN FINIAL POINT.

NRTF 0504.2 x 25 wafer

head self drilling screws

(11 per tile).

34

NRES 004 4.8 x 32 pan head self drill screw (2 per cap)

NRHB002 Aluminium hip spine end plate

GEORGIAN INSTALLATION SOLID ROOF CAPPINGS

1

Centralise ridge to cap over apex. Position 5mm away from host wall. Foam ll void, prior to dress leading.

2

Pre-drill ridge cap at max 750 centres, 6mm holes.

Fix ridge top capping using 5.5mm x 90mm (NRRSA 005BL) provided. Ensure hip spines are aligned with corners of ridge top capping.

3

4a

Fit hip spine end caps. NOTE: (NRES 004) end cap xing screw comes complete with 2 part coloured screw cap cover.

5

Clip t hip capping, ensure xing clips are set at 500 centres (pre - tted clips). In Georgian / Edwardian

situation the hip bar cappings are pre - mitred to abut ridge top capping. NOTE: 3 AND 5 FACET VICTORIANS. THE HIP BAR CAPPINGS AT THE RADIUS END REQUIRE LMEC 004 FITTING, THESE SIMPLY SILICONE AND PUSH FIT ONTO THE END OF EACH BAR.

6

If using existing ashing, dress down over the roof and ridge area then nish as normal. Flashing may need trimming to t neatly. Apply patination oil to lead for peace of mind (Avoids unsightly lead sulphate run o ). Alternatively install new code 4 lead.

NRRSA 005BL 5.5 x 90mm hex washer head self drilling tek screw (with G16 stainless steel sealing washer)

On 3 and 5 facet victorians after tiling, t the preformed external tile ashing

trim (NRVT001). Secure into position using 2 x screws (NRTS 050) provided.

4b

The hip bar top cappings at the radius end require (LMEC004) tting, these require a bead of silicone applying prior to push tting onto the end of each bar.

4c

35

Screw x PVCu so t channel into head of window frame or base of OSB board (screws not provided).

7

Clip t PVCu fascia board locating upper leg to lower leg of aluminium gutter channel (see cross section detail on page 11).

8

GEORGIAN INSTALLATION SOLID ROOF FASCIA SOFFIT AND GUTTERING

9

Fit gutter bracket by placing lower leg onto aluminium gutter channel then ‘snap back’ upper leg. Space at maximum 750mm centres and within 200mm of corner.

10

Fit PVCu fascia corners with silicone.

Fit Marley Classic guttering. Ensure when tting the gutter you t to the insertion marked lines within the unions / gutter corners.

11

12

Extended so t in detail (must be used above super-insulated columns). Silcone seal to retain fascia into ‘H’ section and so t innto ‘U’ channel.

13

Standard so t in detail. Silicone seal ‘U’ channel to retain lower edge of fascia.

36

DOWN LIGHT INSTALLATION

1

The cables can be passed through the grommet and chased above or between the internal battens as shown. Internally, the wiring should be passed beneath the mineral woolinsulation (see inset diagram).

2

Cut a hole in the base of the pelmet for your light tting. Cut a corresponding 20mm dia. hole in the vertical face and t a rubber grommet.

At lower pitches, when only one batten is tted, the hole (and grommet) are positioned lower on the vertical face and the batten split to allow cable access.

3

4

If the light is coincident with one of the internal foam llets (de ned by the marking on the vertical face) it must be positioned in the190mm safe zone.

5

At pitches lower than 17 degrees there is insu cient space on the vertical face to t the 20mm grommet. Drill 2 holes either side of the light xing to allow installation of the wires

as shown. A ‘channel’ can be created using 2 narrow strips of plasterboard covered with a top panel.

Drill through the OSB and vertical face creating the wiring access. The size of the tting may require additional space.NOTE: The cavity should not exceed 130mm from the underside of the beam face

6

THE ULTRAROOF380 BEAM IS NOW INSULATED WITH MINERAL WOOLThis guide shows our recommendations when installing internal down lights in the Ultraroof380 beam. All electrical work must be carried out by a quali ed electrician and tested in accordance with current BS7671 IEE wiring.

THE ULTRAROOF380 BEAM IS NOW INSULATED WITH MINERAL WOOL

37

PLASTERBOARD GUIDELINES

Solid Roof

Glazed Roof

25mm battens to roof panels(Not Supplied)

12.5mm Foil-backed Plasterboard(Single layer – solid roof)

25mm battens to internal beam(Not Supplied)

12.5mm Foil-backed Plasterboard(Double layer –glazed roof *)

25mm battens to roof panels(Not Supplied)

25mm battens to internal beam(Not Supplied)

Eaves Glazed zone

Pitch 15 20 25 30 35 40‘A’ Solid Roof 25 59 92 127 163 202‘A’ Glazed Roof 29 63 98 134 172 212

LVAR multiboard(Supplied)

PVCu PlasterboardTrim (Not Supplied)

20mm batten(Not Supplied)

* Boardintersection

LVAR multiboard(Supplied)

PVCu PlasterboardTrim (Not Supplied)

* Note: Double layer of plasterboard on internal beam upright ensures a single plasterboard seam where ceiling, beam and glazed area boards intersect.

Ridge Glazed Zone

Internal Pelmet Height Calculator

A

A

38

PLASTERBOARD GUIDELINES

Solid Roof

Glazed Roof

Align boards to form a single seamAt internal corner of beam

Variations on Brickwork * Note: Double board if roof features glazing

Attach plasterboard to masonry using timber or metal stud frame. Double board if roof is glazed

Lean-to at 12.5 Degrees

*

*

Attach plasterboard to masonry using timber or metal stud frame

39

PLASTERBOARD GUIDELINES SUPER INSULATED COLUMNS

1

Loggia column

Additional 12mm OSB cladding installed on internal face of super-insulated column. Note: Column aligned 25mm inset from internal beam.

2

3

Finished plasterboard view with board xed to 12mm OSB cladding.

4

Plasterboard in ll to battens adjacent to 12mm OSB cladding.

Finished plasterboard, internal view.

5

25mm

Double board adjacent to OSB cladding

Additional 12mm OSB cladding on internal Loggia face (supplied)

Existing external

loggia OSB cladding

40

INSTALLATION FITTING ROOF GLAZING

FOLLOW MAIN GUIDE UP TO PAGE 11, STEP 28 THEN FOLLOW THIS SECTION

TRANSOM ‘A’ FRAME BAR (GLASS)

TRANSOM INTERMEDIATE BAR (GLASS)

TIMBER TRANSOM ‘A’ FRAME BAR (SOLID)

TIMBER TRANSOM INTERMEDIATE BAR (SOLID)

RIDGE BEAM

STARTER ‘A’ FRAME BAR (GLASS)

STARTER ‘A’ FRAME BAR (SOLID)

GLAZING PANEL

KEY

41


42

GEORGAN

Glass

Glass

Glass

Glass


1

When installing 24mm double glazed units, the box beam OSB face will be marked with the vertical lines which indicate glazing bar centres. On the marked lines, locate to the top edge of the box beam the appropriate box beam shoes (NRBE 001 or NRBE 002) supplied. Fix to the beam using 8 x 4.2mm x 25mm wafer head self drill screws (NRTS 050) provided.

2

THE MAIN GLAZING GUIDE IS BASED ON THIS DESIGN

Drop into position the wall abutment panels, one either side of the ridge (see steps 35-37, page 23). Then the front centre panel (step 38, page 24). From location plan, continue to install all remaining sip panels in pairs, remembering to t the ridge couplers as you go.

3

4

Each glazed area as 2 x ‘A’ frame glazing bar assemblies. These comprise 2 x glazing bars and 1 x adjustable connection bracket (NRAB 001). Attach the bracket to the pre drilled glazing bar using 4 x 4.2mm x 25mm wafer head self drill screw (NTRS 050) provided.

5

When glazing either side of ridge, lower into position. The pre-manufactured ridge purlin cassettes (OSB boarded side nearest the ridge) the bottom edge hooks to the ridge side (like a solid panel).

Lower the glazing bar (with bracket attached) into place along the top of the timber batten and into the already tted box beam shoe.

6

4

Lift the opposite glazing bar into position (to create ‘A’ frame). When aligned, secure the bracket again using 4 screws (NRTS 050) provided. The ‘A’ frame is not to be xed further at this stage. Assemble

and position opposite facing ‘A’ frame as above.

5

Glazing bar in position. If two glass panels sit side by side, intermediate bar must be installed. Mark a centreline on the glazing ridge spacer beam (see location plan). Mark a line 31mm to left and right of centreline then attach 2 x ‘U’ shaped brackets (NRRA001) using 4 x 4.2mm x 25 screws (NRTS 050) provided, for each bracket.

6

43


NRTS050 4.2 x 25mm wafer head self drilling screws

10

Adjust glazing ridge beam height using thumb screws to ensure glazing gaskets are in aligned.

11

Locate the glazing ridge/spacer beam into the adjustable bracket shoes. Check ‘A’ frames are parallel to each other.

‘A’ frame being fastened into box beam shoe.

12

13

Ensure glazing section is square, checking diagonals are equal. Secure adjustable connection bracket into ridge spacer beam using 4 x 4.2mm x 25mm (NRTS 050) provided. Repeat on opposite side of ‘A’ frame.

14

Locate the intermediate glazing bar into the installed ‘W’ brackets.

Again, check intermediate bar for squareness, then secure with 4 x 4.2mm x 25mm (NRTS 050) provided. Repeat on opposite side

15

16

Secure glazing bar to external face of box beam. Two screws each side using (NRTS 050) provided.

17

Fix all glazing bars into box beam shoes, again, using 4 x (NRTS 050) for shoe (NRBE001) or 6 x (NRTS 050) for shoe (NRBE002) provided.

Temporarily remove lower timber batten to allow xing through upper batten. Secure all glazing bars by xing through the upper panel batten at 500mm ctrs. using 4.8mm x 80mm baypole screw self drill Philips wafer head (BPS010) provided. IMPORTANT: ANY GAP BETWEEN GLAZING BAR AND UPPER PANEL BATTEN NEEDS PACKING TO ENSURE NO FLEXING OF GLAZING BAR.

18

44

19

Next, locate aluminium glazing support trims between glazing bars. See inset for location point.

20

Ensure ridge purlin cassette sits square to underside of glazing bar, check bottom hook is located onto ridge and in-line with hooks on adjacent panels by pulling forward. Fix into place using 1 x xing 4.8 x 80mm (BPS010) provided.

Secure the glazing support section at 200mm ctrs. using 4.2mm x 25mm wafer head self drill screws (NRTS050) provided.

21

22

Fix through each side of the purlin cassette into the panel edge using (BPS010) provided.

23

Screw up through ridge section into purlin cassette at 300mm ctrs. using 5.5mm x 32mm hex head drill screw (RRR025) provided.

Now t the tile screen framework (OSB board uppermost) position this 6mm back from purlin cassette front edge (TIP: use 6mm architrave supplied to set position). Fix at 300mm ctrs using xing 4.0mm x 40mm (NRBF050) supplied.

24

25

Where glazing is present, allow the membrane to overlap into the glazing bar as shown. The drainage channel can then be installed to clamp the membrane in place.

26a

Now re t the lower panel batten (which was removed at step 18). Fix using 5.0mm x 50mm c’sunk pozi head x wood screws (RRX025) provided.

RRX025

NRBF050

Tape the joint between the breather membrane and drainage channel as shown using weathering tape (supplied).


26b

45

27

Fit the glazed ridge panel ashing trim to left and right side of ridge, (NRRI 011R right shown). These are bedded down using clear low modulus silicone provided.

28

At each side of the glazing area, an aluminium upper tile stop is tted. The lower edge of the tile stop is positioned a set distance from the edge of the bottom tile starter support. See critical dimension sheet for dimension A, see step 29. The tile stop is bedded down with clear low modulus silicone, then screwed at 300mm ctrs using (NRSF012) 4.8 x 38 pan head screws provided. Finally seal lower edge of the tile stop to underlayer again using clear low modulus silicone.

29

30

Lay carefully into position the 24mm thick double glazed unit tight to the upstand on the lower glazing support section. See seperate detail if tting roof vent.

31

Position the box beam tile screens. Place in-line with adjacent tiling (not covering ventilation mesh) and secure with a single 4 x 40mm screw top centre (NRBF 050) provided.

Prior to tting the pre-notched glazing end pro le, run a bead of silicone, low modulus (for none coated glass) or MS Polymer (self clean glass) immediately behind the co-extruded gasket before tapping down into position. Then seal each end to protect the seal.

32 33

Fold the rubber sealing tabs over the top of each glazing bar.


A

Dimension A given on critical dimension sheet. This gives distance from face of tile stop to outer edge of tile starter support.

NOTE: CHECK FOR 30MM SPACE BETWEEN OSB BOARDS. THIS WILL ENSURE INNER TOP CAP SEALS ARE POSITIONED CORRECTLY ON THE TILES STOPS.

15mm 15mm

46

36

Over solid panel area screw down either side of the capping at 500mm ctrs into the upper tile stop using (NRTS 050) screws provided.

37

Lay aluminium ridge ashing cap. It is positioned 10mm away from the host wall. Then predrill the capping to suit steps 37 and 38.

Over glazed area, also at 500mm centres, screw down through the ridge capping centre line using the longer 5.5mm x 90mm (NRRSA 005BL) screws tted with G16 stainless steel sealing washer. Run a continuous bead of silicone, low modulus (for non coated glass) or MS polymer (self clean glass) along the head of the unit tight to the Q LON gasket.

38 39

Seal and t the front radius end ashing kit using 250 x 250 square butyl sealing tape (supplied). Heat the sealing tape with a heat gun and position the tape over the ridge end (100mm from ridge end). Press rmly into place over the capping then

make 2 slits (as indicated) before forming the nal position.

40

Seal and t the rear host wall pre-formed ashing saddle (NRRI010). Using clear low

modulus silicone.

When tting the glazing top cappings ensure you have the brush seal gasket covering the tiles and the QLon gasket on the glass, prior to knocking the capping down.

41 42

Attach the aluminium transom end cap plates to the end of each glazing bar using 2 x 4.8 x 32mm pan head self drill screw (NRES 004) provided. Each screw comes with a 2 part coloured screw cap cover.


Slide the ridge tile upper screen into position. No xing required.

34

The upper ridge tile screen is trapped by tting 6mm thick black architrave (provided). This will nish ush with the purlin cassette but tight up to the glass unit. Fix at 300mm centres using 4 x 40mm screws (NRBF 050) provided.

35

47

1

From internal frame the front beam overhangs the frames by 94mm (standard so t) and by 170mm (extended so t) equalize so t overhang.

2

ONLY IF GABLE FRAME STIFFENERS SPECIFIED: Fix the aluminium gable beam xing plate to the underside of the box

beam using 6 x RRX 025 screws. NOTE: ALIGN PLATE ‘V’ NOTCH GROOVES WITH EDGE OF BEAM.

For box beam/support and levelling see pages 19 steps 8 to 9.

3 4

Using the measuring sta supplied with the roof, engage the bottom of the guage into the support shelf on the box beam.

5

Temporarily x the half-ridge (cut to internal frame, see image 6) at the height given in the critical dimensions sheet, ensuring the ridge is level. Adjust the half ridge height if necessary. NOTE: DIMENSION IS FROM UNDERSIDE OF BOX BEAM TO TOP EDGE OF HALF RIDGE SEE PAGE 50 .

With measuring sta inserted into the box beam shelf check that the upper end of the sta is aligned with the edge of the hook section on the half-ridge. Pack the half-ridge o the wall if necessary to align in the correct position to box beam. O er up a panel to double check distance and pitch.

6 7

ONLY IF GABLE FRAME STIFFENERS SPECIFIED: Silicone the head of the frames. Place the aluminium gable frame sti ener with V-groove uppermost.

8

Using sta , check in various positions to ensure half ridge is running parallel to box beam. Fully secure half ridge to host wall at 500mm centres using xings appropriate to substrate. Finally secure box beam (see image 21 page 21)

INSTALLATION LEAN TO SOLID

Apply low modulus silicone to the head of frames local to beam area before lifting the box beam into position. Temporarily x the box beam in position.

3

INTERNAL FRAME

48

Fix the gable frame sti ener to the aluminium beam xing plate using 4 x RRR025. Secure along the length of the sti ener at 500mm centres into frames ( xings not supplied). Set out image 10.

9


10

Apply silicone to the gable support extrusion and x the gable frame. Trial t the in ll wedge and coupler prior to nal xing.

11

The 4 xing positions.

Hook the top of roof panels into the half ridge and rest the lower end on the box beam support shelf. Fit all roof panels as shown in the roof panel layout sheet. Ensure barge boards are ush with the end of the beam. See page 23 step 36 and 37 of main guide. NOTE: IF THERE IS GLAZING AGAINST A RETURN WALL SEE PAGE 61.

12 12a

Mark a line on the house wall that is aligned with the top of the battens

13

Screw up into panels through the panel support ledge at 300mm centres through pre-drilled holes in half ridge to secure the panels using RRR025 hex head screw 5.5 x 32mm provided. If panels attaching to return wall (see steps 47 and 48 on page 25 of the main guide)

Fix the batten provided to the wall on the line marked in 13. This provides support for the roof deck as it meets the house wall.

14 15

IMPORTANT: ENSURE BOTTOM ROW OF OSB IS FIXED AS PER IMAGE 55 PAGE 26 OF THE MAIN GUIDE AS THIS LOCKS TOGETHER BOX BEAM TO PANEL.

16

Fit batton extensions and OSB baording as per steps 52 to 58, pages 26 and 27 of main guide.

49


18

Fix the end cap in place using the NRES 004 4.8 x 32 pan head screw with cover caps.

19

Insert the aluminium dry verge end cap into a square cut end. The end adjacent to the house will be angled to run parallel with the house wall.

Apply a bead of clear low modulus silicone to the underside of the dry verge.

20 21

Fix the dry verge to the OSB using NRTS 050 screws at 300mm centres.

22

Position the dry verge on the top edge of the bargeboard, with the membrane folded down the face of the barge board.

Fix the dry verge to the roof deck with NTRS 050 screws, max 300mm centres

23 24

If obstructed on the RHS, remove 15mm from the clips to allow tting.

25

See p29 and the tiling guide in the tile box for details on tiling method.

Cut the breathable membrane underlayer to the width of the roof deck plus 50mm over hanging the OSB barge-board at each end and 150mm up the host wall. See page 27 steps 62 to 65 for minimum overlaps.

17

50

Fit so t trims to underside of barge boards.

26 27

Fit 90° external corner cover trims

28

Fit pvc barge board box ends and barge board

Fit internal and external gable sti ener claddings (if ordered)

29 30

Lead ash to exiting host wall.


LEAN TO SOLID ROOF HALF RIDGE CROSS SECTION

*Set out height given on critical dimension sheet/INSTALLATION - GABLE END - SOLID

*

NOTE: HIPPED LEAN TO1. Box beam will return to host wall.2. Centralise half ridge (if hipped

each end).3. Attach hip bar to speedlock

housing.4. Remainder as Georgian

51

INSTALLATION LEAN TO GLAZED

Follow main guide then follow this section.

GLAZING

PANEL STARTER (GLASS)

TRANSOM

TRANSOM INTERMEDIATE BAR

TRANSOM TRANSOM STARTER STARTER

52

1

Temporarily x the half ridge (cut to internal frame, see image 1) at the height given in the critical dimensions sheet, ensuing the ridge is level adjust the half ridge height if necessary. NOTE: DIMENSION IS FROM UNDESIDE OF BOX BEAM TO TOP EDGE OF HALF RIDGE.

2

Position front box beams on frames. Ensure equal overhang at each end. Support / prop and level as page 19 steps 8 and 9.

When tting intermediate transom glazing bar(s), the centre line of each bar is marked on front box beam. Check centres match roof plan then transfer to rear half ridge. Ensure intermediates are set parallel and square to transoms. Then t pre-cut glazing support trims.

3 4

Fix intermediate glazing bar shoe secure into OSB using 2 x CHA006.

5

Hook onto rear half ridge and secure upper leg using 2 x NRES 004, 4.2mm x 25mm screw.

Locate intermediate bar into shoe on half ridge and shoe on box beam.

6 7

Silicone seal the head of the glazing bar.

8

Secure using 4 X (NRTS 050) screws. Ensure glazing bar gaskets align with glazing support trims. (Pack o timber purlin cassette if required.


2a

Secure transom bars to upper panel battens (see page 43 step 18). Ensure glazing gasket aligns with top of glazing support trim tape (see inset). You may need to pack o upper panel batten to achieve this.

NOTE: INTERMEDIATE TRANSON BAR SHOW AT STEP 3 ONLY USED WHEN 2 GLASS PANELS SIT SIDE BY SIDE.

53

10

1200mm lengths of CODE4 lead overlapping 150mm and protruding 50mm, beyond nose of top capping to be used. Coat with patination oil to avoid oxidation run o .

11

Centralise and t half ridge aluminium top capping. Secure using (CHA006) at 500mm centres. Beware: Longer screws will penetrate glass units.


Prior to glazing, insert the tile screen framework. (See step 19 page 44). Position box beam tile screen (see step 30 page 45). Insert double glazed unit (then follow steps 32 to 35 page 45).

9

54

1

Starter bar rides over the front box beam and drops into box beam shoe. Secure the shoe with 2 x (NRTS 050) screws.

2

Set the half ridge (wallplate) 5mm away from the host wall. The height (as step 6 page 47). Upper end of starter bar positioned so that glazing gasket aligns with glazing support trim. Secure to host wall within 200mm of half ridge and box beam plus at least one more equidistant between the two. Use resin anchors suitable to substrate - not provided.

Seal top edge of starter bar bung (NRRA002). Place the bung tight into the junction of the host wall and starter bar. Then seal with clear low modulus silicone.

3

4

Secure the half ridge top capping into starter using (CHA006) screws provided.

5

Silicone the edge of the bung against the starter bar.

Using butyl tape supplied, ensure adequate seal between top capping and starter bar upstand.

6

7

Finally, manipulate code 4 lead over the glazing bar top capping and half ridge capping with overplaps as step 11 page 53.

INSTALLATION LEAN TO GLAZED TO ADJACENT WALL

Refer to Lean to solid section of this guide to complete

55

1

Apply low modulus silicone to the head of frames local to beam area before lifting the box beam into position. Temporarily x the box beam in position.

2

Fix the aluminium gable beam xing plate to the underside of the box beam using 6 x RRX 025 screws. NOTE: ALIGN PLATE ‘V’ NOTCH GROOVES WITH EDGE OF BEAM.

For box beam/support and levelling see pages 19 steps 8 to 9.

3

Silicone the head of the frames. Place the aluminium gable frame sti ener with V-groove uppermost.

4

Fix the gable frame sti ener to the aluminium beam xing plate using 4 x RRR025. Secure along the length of the sti ener at 500mm centres into frames ( xings not supplied). Set out image 10 page 48.

5

INSTALLATION GABLE END SOLID

Apply silicone to the gable support extrusion and x the gable frame. Trial t the in ll wedge and coupler prior to nal xing.

6

After installing the ridge as detailed in pages 22 and 23, images 25 to 30, check that the end of the ridge is in line with the gable end internal frame line.

7

Referring to the panel layout sheet, t the rst panels at the gable end as shown in

images 35 to 37 on page 23.

8

Check that the panel is in line with the end face of the beam and parallel to the gable frame.

9

56

10

Refer to pages 25 to 27 when fi xing the panels, insulation osb and membrane.Note: ensure the membrane extends 50mm beyond the gable end panels.

11

Continue tting the panels from the host wall, remembering to install the ridge coupler assembly shown on page 24 images 39 to 43

When glazing refer to pages 40 to 46, images 1 to 42.

12

13

Fit gable cladding alignment strip intothe aluminium dry verge.

14

Fit one side of the dry verge as shown in steps 18 to 23 on page 49.

Fit opposite aluminium dry verge and point joints on upper and inner edges.

15

16

Continue referring to page 46 images 36 to 39.

17

Slide tile stop under dry verge and xed in place. See page 45 images 27

to 29 for details.

Fit the gable ashing. Mark and trim to t the dry verge.

18


57

19

Fit rst 200mm Butyl tape strip sealing the gable ashing to the ridge ashing cap.

20

Apply clear low modulus silicone to the faces shown and re t.

Fit second 200mm Butyl tape sealingthe dry verge to the gable ashing.Cut the tape to allow it to be folded as shown in the following two images

21

22

Finally cover joint with a third layer.

23

Fold down and press rmly into position.

Fit the ridge top capping using the NRRSA 005BL supplied.

24

25

Fit the pre-cut fascia and eaves trims.See page 50, images 26 to 29for more detail.

26

Apply clear low modulus silicone to the joint between the ridge top cap and the dry verge.

Fit the fascia ridge trim, modifyingwhere necessary ensuring a neat nish.

27


58

The gable apex cover is a product for an improved nish at the exterior apex of a duo-pitched gable roof. This new 2-part product is used to cloak the joint between two adjoining dry verge claddings.

Scribe the lower part to t beneath the step in the aluminium dry verge cladding as shown. Fix using a suitable silicone adhesive.

1

2

Position as shown and x using 2 x NRTS 4.2 x 25 self drilling wafer head screws (supplied).

3

Bend the wings of the upper part to match the desired roof pitch – by default they are set to 25 degrees.

Finished installation shown above.

4

INSTALLATION GABLE APEX COVER

25°

NRGC002/2 NRGC002/1

59

INSTALLATION GABLE REINFORCEMENT BOX DETAIL

GABLE REINFORCEMENT BOX

A

1 FRAME STIFFENERTERN CLADDING

SUGGESTED 10mmREDUCTION IN FRAME SIZE FOR NEW BUILD TO ALLOW FOR SETTLEMENT

40

5.175 SECTION I-I

IFL

UNDERSIDE OF BEAM

GABLE REINFORCEMENT BOX SECTION(SEBA---/4)80 x 120 x 6.75mm

WINDOW SUPPORT L SECTION (RRP---/4)SENT FULL LENGTH OF GABLE ATTACHED FULL LENGTH OR CUT TO SIZE AS REQUIRED ON SITE

STUB CILL NOT SUPPLIED

TRIM NOT SUPPLIED

ONSITE

CEMENT

GABLE REINFORCEMENT BOX SECTION FIXED TO BRACKET

COUNTERSINK HOLES

Detail may vary if tting on brickwork. Refer to brickwork section.

NOTE: A cill will be required if on super-insulated columns

60

INSTALLATION GABLE REINFORCEMENT BOX DETAIL

A

2mm OFFSET

DETAIL A

REINFORCEMENT CUT SQUARE AT INTERNAL FACE OF BEAMPACK OUT AREA UNDER BEAM ONSITE OR CAP EXPOSED END OF REINFORCEMENT BOX [PACKING OR END CAP NOT SUPPLIED]

NRRB001GABLE REINFORCEMENT BRACKETFIXED TO BEAM ONSITESEBA---/4GABLE REINFORCEMENT BOX SECTION80 x 120 x 6.75mm

GABLE REINFORCEMENT

REPLACES NRFS---/1 FRAMAND SSPC--- LANTERN C

CAD MODEL IS MA

WINDOW SUPPORT L SECTION

GABLE REINFORCEMENT BOX SECTION FIXED TO BRACKET

COUNTERSINK HOLES

G O

INTERNAL FRAME LINE

GABLE REINFORCEMENT BRACKET(NRRB001)FIXED TO BEAM POCKET ONSITE

GABLE END OF BEAM

61

GABLE SYSTEM OVERVIEW SECTION THROUGH STANDARD SOFFIT

50mm overlap

44mm

STANDARD SOFFIT

ALUMINIUMDRY VERGE

GABLE EDGING (PRE-FITTED TO PANEL)

EXTERNAL FASCIA

GABLE TIMBER (PRE-FITTED TO PANEL)

9mm MULTIBOARD

GABLE FRAME

RIDGE BODY (ALIGNED WITH GABLE FRAME)

PANEL

TILE STOP(INSERTED INTO DRY VERGE)T&G OSB BOARD

RIDGE FLASHING CAP(ALIGNED WITH DRY VERGE)

WATERPROOFMEMBRANE

62

GABLE SYSTEM OVERVIEW SECTION THROUGH EXTENDED SOFFIT

EXTENDED SOFFIT

GABLE TIMBERS (PRE-FITTED TO PANEL)

63

BOX BEAM ON SUPER INSULATED COLUMN

25mmCOLUMN EXTERNAL FACE TOBOX BEAM EXTERNAL FACE

207.50mm EXTENDED SOFFIT ONLYON SUPER-INSULATED COLUMN

If your installation contains a super-insulated column, then it is possible to support the box beam on the column providing that the beam is installed with the following details.

EXTENDED SOFFIT ONLY ON A SUPER INSULATED COLUMN

64

INSTALLATION INTERNAL EXTERNAL FINISH TUDOR

1

Batten out to suit plasterboard xing.

2

NO MATERIALS SUPPLIED FOR THIS FINISH. Attach corner beam support shelf

Attach additional battens.

3

4

Fix into position.

5

Slide into position additional external OSB board.

Plasterboard the roof.

6

7

Fix into place.

8

Fabricate 70 x 45mm triangular studding framework to suit.

Attach additional mating timber battens.

9

65

INSTALLATION INTERNAL EXTERNAL FINISH TUDOR

10

Plasterboard face of gable

11

Insulate void with mineral wool. Fit external so t channeling.

12

13 14

Fit external ship lap cladding edge channel.

Cut and t ship lap to suit.

15

External ship lap cladding edge channel detail.

66

PLEASE READ BEFORE FITTING

SUPPLIED COMPONENTS Below shows the various components that should be supplied as a beam joining on post kit.

BEAM FIXING SCREW5.0 x 50 C’SNK pozi heco fix

wood screw

NRSP0012500mm Post Sleeve with beam joing plate

RRF004Post base plate

with spigot

POST COUPLING BOLT M12 x 110 SOCKET CSK SCREW

X1 X1 X12 X2

X2

WASHER NUT

X2

NRSK001Fixing Kit

INSTALLATION BEAM JOINING POSTThis document shows how to join two Ultraroof380 Beams that are over 7m+ onto a stanchion post.

1

Measure from the surface the post will sit on to the top of the window frames, this will drive the length of the post sleeve (NRSP001)

2

NOTE: The post can be placed either at floor level or on top of a dwarf wall. Guide will show instruction from dwarf wall level.

Cut the post sleeve (NRSP001) to the length measured in step 1

3surface to

window frame top

FITTING THE POST

Cut

surface to window frame

top

67

INSTALLATION BEAM JOINING POST

4

Align the two sections as shown in the image above.

5

Slide the base plate(RRF004) all the way into the cut post sleeve.

Secure the two sections together using the fixing bolts provided. Drill a 13mm hole through both sections and counter sink, secure with nuts provided.

6

7

Fix the post into the brick (FIXING NOT SUPPLIED)NOTE: CILL MAY REQUIRE NOTCHING

8

Offer up the post onto the brick work; maintain a 20mm gap between the post and the external brick internal/window frame. Make sure the post is in the correct orientation. (SEE STEP 1)

Once secured, place the first box beam onto the post followed by the second beam.

9

10

Use the extra cleats provided to secure through the metal sections of the box beam. (see above image)

11

Once both beams are in place, secure the post into the beams. (Fix through the 12 counter sunk holes using the screws provided.)

Insulate between the post and the external brick when post is set within the cavity wall.

12

Top plateBase plate

20mmbetween post and window frame

Fix cleat

Fix cleat

Insulate (not supplied)

Job No.: 3223 2/18 V4 NRIG001 It is Ultraframe’s policy to continually seek to improve its products, processes and services, and we reserve the right to change speci cations without prior notice. Ultraframe is a trading name of Ultraframe (UK) Limited.

www.ultraframetrade.co.uk

3223 ultraroof380 installation A4 68pp AW JAN 2018 MAIN · 6 Fixing panel to beam 300mm CTRS RRR...

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Transcript of 3223 ultraroof380 installation A4 68pp AW JAN 2018 MAIN · 6 Fixing panel to beam 300mm CTRS RRR...